3-SPEED TRANSMISSION TEARDOWN GUIDE

Transcription

1 3-SPEED TRANSMISSION TEARDOWN GUIDE Toro Service Training Material 3-Speed Transmission Teardown This is an exercise to take apart a 3-Speed transmission just as you would if one fails on a customer s unit. We want to show you how to take it apart and put it together, as well as give you ideas of what to look for as possible causes of failure. Whenever a transmission is taken apart, clean all of the grease off of the parts and out of the gearcase. This will get any metal filings out of the gearcase which can cause future problems. During reassembly of the gearcase, put 6 oz. of #2 Lithium grease in the gearcase. Putting grease between the individual gears is not necessary and can, in some cases, cause shifting problems. 3-Speed Transmission Teardown During the teardown of the transmission, have the gearcase cover facing upwards. 1. Remove the six 3/8" bolts which retain the gearcase cover. 2. Remove the shift fork retainer and yoke fork retainer bushing. 3. Remove the output shaft assembly. 4. Disassemble the output shaft, lining up the parts in the order that they are removed. 5. Inspect the gears and keys for wear. Possible areas for wear or damage shift keys - detent area - key engagement area gears - ramp area for wear or chips - key contact area - teeth for wear and missing teeth due to mismatch with input shaft gears, or pinion gears shift key - detent area for wear sleeve NOTE: If a gear needs to be replaced for any reason, replace the keys and retaining clip at the same time. 3-SPEED TRANSMISSION TEARDOWN GUIDE Page 1 of 5

2 Assembly 1. Put the shift key sleeve assembly together. a) Place the shift keys in the shift key sleeve with the key engagement area toward the hub, but not through the hub. b) Slip the shift collar over the other end of the keys. c) Stand the shift key sleeve up with the collar facing up. d) install the spring clip. NOTE: Always replace the spring clip at any time the keys are replaced. e) Leave the keys in the neutral position which is when the keys are flush with collar end of the shift key sleeve. 2. Place the shift key sleeve on the output shaft with the hub toward the gear sleeve. 3. Install the 1st gear (49 tooth) from the right hand side. Have the thrust surface toward the right hand (long end) of the shaft. 4. Install 2nd gear (44 tooth) (same as step 3). 5. Install 3rd gear (39 tooth) gear (same as step 3). 6. Slide keys to first gear position and check key and gear alignment. Repeat this with 2nd and 3rd gear. 7. On left hand side (short side), install thrust washer and thinner output shaft bushing. 8. On right hand (long side) install thicker output shaft bushing. 9. Set aside for reassembly. Intermediate Shaft 1. Remove the intermediate shaft from the transmission. 2. Clean the gear set. Inspect for any wear on the pinion gears, and replace as necessary. 3. If a pinion gear replacement is required, the 15 tooth pinion gear with bevel gear is on the left hand side of the transmission. Two thrust washers are installed on the left hand side between the gear and bushing. The 2nd (20 tooth) and 3rd gear (25 tooth) can be installed in any direction on the shaft. 3-SPEED TRANSMISSION TEARDOWN GUIDE Page 2 of 5

3 Reassembly of Gearcase 1. With no grease in the gearcase, install the intermediate shaft. 2. Slip the shift fork over the shift collar. Align the shift fork with the hole in the gearcase and slip the complete output shaft into the gearcase. NOTE: For ease of reassembly, leave the shift keys in the neutral position. 3. Install the yoke bushing on the shift fork. 4. Install the shift yoke over the shift bushing and into the recess of the case. 5. Distribute 6 oz of #2 Lithium grease evenly in the gearcase. 6. Reinstall cover and self-tapping retention screws. 7. Torque the screws to in-lbs. 3-SPEED TRANSMISSION TEARDOWN GUIDE Page 3 of 5

4 3-SPEED TRANSMISSION TEARDOWN GUIDE 3-SPEED TRANSMISSION TEARDOWN GUIDE Page 4 of 5

5 WHEEL PINION CLUTCH ASSEMBLY GUIDE 3-SPEED TRANSMISSION TEARDOWN GUIDE Page 5 of 5